Wind generating set state monitoring system based on infrared thermal imaging

Abstract

The utility model relates to the technical field of infrared thermal imaging, in particular to a wind generating set state monitoring system based on infrared thermal imaging. The system comprises an infrared thermal imager, a thermocouple sensing unit and a data acquisition card, the infrared thermal imager and the thermocouple sensing unit are installed in a cabin of the wind power generation equipment and used for acquiring temperature data in the cabin, and the data acquisition card is installed in a control cabinet of a wind power generator and used for acquiring temperature data in the cabin. The data acquisition card is respectively connected with the infrared thermal imaging unit and the thermocouple unit through data lines and is used for fusing thermal imaging and thermocouple data, and the data acquisition card uploads the fused data to an upper computer. According to the utility model, data of the infrared thermal imager and the thermocouple sensor are fused through the data acquisition card, so that the monitoring accuracy of the system is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of infrared thermal imaging, in particular to a wind turbine generator set state monitoring system based on infrared thermal imaging. Background Art

[0002] In the existing technology, wind power generation plays an increasingly important role as a clean and renewable energy form. However, the maintenance of wind turbines after installation has always been a key factor affecting their reliability and profitability. After the warranty period, effective maintenance work is particularly important. In the past, operators mostly adopted a passive maintenance strategy, that is, waiting for equipment failures before repairing them. However, this method often leads to extended downtime and increased maintenance costs, which seriously affects the normal operation and power generation efficiency of wind turbines. The various components of wind turbines are very easy to wear in long-term operation, and failures occur from time to time. Therefore, implementing preventive maintenance and regular inspections have become a way to ensure the stable operation of wind turbines. Key measures: Infrared thermal imagers can quickly provide an overview of the thermal characteristics of wind turbines. This convenient feature greatly improves inspection efficiency and reduces the time required to troubleshoot problems. However, the interpretation of infrared thermal imaging images in current infrared thermal imagers requires certain professional knowledge and experience, which may be difficult for non-professionals and easily lead to misjudgment. In addition, in certain complex environments or specific conditions, the temperature measurement accuracy of infrared thermal imagers is easily affected by the environment, including factors such as ambient temperature, humidity, and surface characteristics of objects, which in turn affects the accuracy of infrared thermal imaging. At this stage, a wind turbine status monitoring system based on infrared thermal imaging is needed. Utility Model Content

[0003] In order to solve the problems that image interpretation in infrared thermal imaging devices is difficult and the accuracy is easily affected by external factors, the utility model provides a wind turbine generator state monitoring system based on infrared thermal imaging.

[0004] The utility model provides a wind turbine generator status monitoring system based on infrared thermal imaging, which adopts the following technical solutions:

[0005] A wind turbine generator condition monitoring system based on infrared thermal imaging, comprising:

[0006] An infrared thermal imager, a thermocouple sensor unit and a data acquisition card, wherein the infrared thermal imager and the thermocouple sensor unit are installed in the cabin of the wind power generation equipment and are used to collect the temperature data inside the cabin. The data acquisition card is installed in the control cabinet of the wind turbine. The data acquisition card is connected to the infrared thermal imager and the thermocouple unit respectively through a data cable and is used to fuse the thermal imaging and thermocouple data. The data acquisition card uploads the fused data to a host computer.

[0007] Furthermore, the infrared thermal imager has a built-in embedded memory and an image processor, the embedded memory stores thermal images of the interior of the cabin under normal conditions, the embedded memory is connected to the image processor to provide reference images, and the infrared thermal imager adopts a dual-lens infrared thermal imager.

[0008] Furthermore, an adjustment base is provided on the lower surface of the infrared thermal imager, and the infrared thermal imager is installed at a side position close to the gear box and the bearing in the cabin through the adjustment base, and the lens of the infrared thermal imager faces the rear end position of the gear box.

[0009] Furthermore, the adjustment base includes a mounting plate and a support frame, the mounting plate is vertically connected to the upper end of the support frame, an arc-shaped support plate is provided between the mounting plate and the support frame, an adjustment groove is provided on the surface of the mounting plate, and the infrared thermal imager is connected to the inside of the adjustment groove through an adjustment bolt.

[0010] Furthermore, the thermocouple sensing unit is fixed to the gearbox and the bearing surface inside the cabin by means of a fixing fixture, and the thermocouple sensing unit transmits data to a data acquisition card by means of a thermocouple wire, and a protective sleeve is provided on the outside of the thermocouple wire.

[0011] Furthermore, the thermocouple sensing unit includes a first thermocouple sensor and a second thermocouple sensor, and the first thermocouple sensor and the second thermocouple sensor are both connected to a signal input terminal of a data acquisition card through a thermocouple wire.

[0012] Furthermore, the fixing clamp includes a first fixing clamp and a second fixing clamp, one side of the first fixing clamp is an annular clamp, and the other side of the first fixing clamp is provided with a wire groove, the annular clamp is connected to the outer side of the wire groove by a fixing bolt, and is used to fix the first thermocouple sensor to the bearing surface, and the thermocouple wire is distributed inside the wire groove.

[0013] Furthermore, the second fixing fixture adopts an adhesive fixture, which fixes the second thermocouple sensor to the metal surface outside the gearbox. The probe of the second thermocouple sensor is connected to the inlet and outlet of the oil cooler of the gearbox in a fitting and abutting manner to monitor changes in oil temperature.

[0014] Furthermore, the data acquisition card includes a clock source, a timing controller and an embedded processor. The clock source is respectively connected to the timing controller and the embedded processor for providing a clock signal. The timing controller is respectively connected to the first thermocouple sensor, the second thermocouple sensor and the infrared thermal imager through an analog-to-digital converter. The timing controller is connected to the embedded processor for synchronous signal acquisition.

[0015] Furthermore, the data acquisition card has a built-in 4G communication network, and the data acquisition card uploads the fused thermocouple sensor data and infrared thermal imager data to a host computer through the 4G communication network for real-time data analysis.

[0016] In summary, the utility model has the following beneficial technical effects:

[0017] 1. The utility model combines an infrared thermal imager and a thermocouple sensor. The infrared thermal imager can provide a large-area temperature distribution image and quickly discover abnormal temperature areas. The infrared thermal imager and the thermocouple sensor data are fused through a data acquisition card. When the temperature measurement of the infrared thermal imager is affected by the environment, the thermocouple sensor data can improve the accuracy of temperature monitoring and adapt it to different environmental conditions in wind power generation.

[0018] 2. The embedded memory built into the infrared thermal imager of the utility model stores the thermal image of the cabin interior under normal conditions, and compares the real-time acquired thermal image with the thermal image through the image processor, which makes it possible to quickly and accurately find the difference between the current thermal image and the normal image, making image interpretation simpler. In addition, the utility model adopts a dual-lens infrared thermal imager, which can obtain richer temperature information and a wider field of view.

[0019] 3. The utility model performs data synchronous acquisition through a data acquisition card including a clock source and a timing controller. The clock source provides a stable clock signal for the timing controller and the embedded processor, ensuring the accuracy and synchronization of data acquisition, which helps to capture the temperature data of the thermocouple sensor and the infrared thermal imager at the same time, thereby improving the reliability of monitoring. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the internal installation of a wind turbine in a wind turbine generator set status monitoring system based on infrared thermal imaging according to an embodiment of the utility model.

[0021] Figure 2 It is a schematic diagram of the structure of the infrared thermal imager in the embodiment of the utility model.

[0022] Figure 3 It is a schematic diagram of the structure of the adjustment base in the embodiment of the utility model.

[0023] Figure 4 It is a schematic diagram of the first fixing fixture structure of an embodiment of the utility model.

[0024] Figure 5 It is a data processing flow chart in the data acquisition card of the embodiment of the utility model.

[0025] Among them, 1. The second thermocouple installation position; 2. The first thermocouple installation position; 3. The infrared thermal imager installation position; 31. The infrared thermal imager lens 4. Adjustment bolt; 5. Adjustment groove; 6. Arc support plate; 7. Support frame; 8. Mounting plate; 9. Infrared thermal imager wire; 10. Wire groove; 11. Fixing bolt; 12. Ring clamp. DETAILED DESCRIPTION

[0026] The utility model is further described in detail below in conjunction with the accompanying drawings.

[0027] Example 1

[0028] Reference Figure 1 , a wind turbine generator set condition monitoring system based on infrared thermal imaging of this embodiment includes:

[0029] An infrared thermal imager, a thermocouple sensor unit and a data acquisition card, wherein the infrared thermal imager and the thermocouple sensor unit are installed in the cabin of the wind power generation equipment and are used to collect the temperature data inside the cabin. The data acquisition card is installed in the control cabinet of the wind turbine. The data acquisition card is connected to the infrared thermal imager and the thermocouple unit respectively through a data cable and is used to fuse the thermal imaging and thermocouple data. The data acquisition card uploads the fused data to a host computer.

[0030] The infrared thermal imager has a built-in embedded memory and an image processor. The embedded memory stores thermal images of the interior of the cabin under normal conditions. The embedded memory is connected to the image processor to provide reference images. The infrared thermal imager adopts a dual-lens infrared thermal imager.

[0031] An adjustment base is provided on the lower surface of the infrared thermal imager, and the infrared thermal imager is installed at a side position close to the gear box and the bearing in the cabin through the adjustment base, and the lens of the infrared thermal imager faces the rear end position of the gear box.

[0032] The adjustment base includes a mounting plate and a support frame, the mounting plate is vertically connected to the upper end of the support frame, an arc-shaped support plate is provided between the mounting plate and the support frame, an adjustment groove is provided on the surface of the mounting plate, and the infrared thermal imager is connected to the inside of the adjustment groove through an adjustment bolt.

[0033] The thermocouple sensing unit is fixed to the gearbox and the bearing surface inside the cabin by means of a fixing fixture. The thermocouple sensing unit transmits data to a data acquisition card by means of a thermocouple wire. A protective sleeve is provided on the outside of the thermocouple wire.

[0034] The thermocouple sensing unit comprises a first thermocouple sensor and a second thermocouple sensor, and the first thermocouple sensor and the second thermocouple sensor are both connected to a signal input terminal of a data acquisition card through a thermocouple wire.

[0035] The fixing clamp includes a first fixing clamp and a second fixing clamp, one side of the first fixing clamp is an annular clamp, and the other side of the first fixing clamp is provided with a wire groove, the annular clamp is connected to the outer side of the wire groove by a fixing bolt, and is used to fix the first thermocouple sensor to the bearing surface, and the thermocouple wire is distributed inside the wire groove.

[0036] The second fixing fixture is an adhesive fixture, which fixes the second thermocouple sensor to the metal surface outside the gear box. The probe of the second thermocouple sensor is connected to the inlet and outlet of the oil cooler of the gear box in a fitting and abutting manner to monitor changes in oil temperature.

[0037] The data acquisition card includes a clock source, a timing controller and an embedded processor. The clock source is respectively connected to the timing controller and the embedded processor for providing a clock signal. The timing controller is respectively connected to the first thermocouple sensor, the second thermocouple sensor and the infrared thermal imager through an analog-to-digital converter. The timing controller is connected to the embedded processor for synchronous signal acquisition.

[0038] The data acquisition card has a built-in 4G communication network, and the data acquisition card uploads the fused thermocouple sensor data and infrared thermal imager data to a host computer through the 4G communication network for real-time data analysis.

[0039] Specific;

[0040] like Figure 1As shown, the infrared thermal imager 3 measures the surface temperature distribution by detecting the infrared radiation emitted by the wind turbine. It can quickly obtain a large area temperature image without contacting the object. Inside the cabin of the wind turbine, the infrared thermal imager 3 is installed at a side position close to the gear box and the bearing. The installation angle of the infrared thermal imager is adjusted so that its lens is biased toward the rear end of the gear box, which is the connection between the gear box and the generator. This position can more directly monitor the temperature of the gear box and the bearing. The infrared thermal imager lens 31 adopts a dual-lens infrared thermal imager with a wider monitoring angle. According to the selected installation position, the adjustment base is fixed to the inside of the cabin to ensure that the infrared thermal imager can work stably and will not shake or shift when the equipment is running. Then the infrared thermal imager wire is connected. The infrared thermal imager wire 9 includes a power line and a data line to transmit the thermal imaging data to the data acquisition card. Thermocouple sensors are based on the thermoelectric effect. A closed loop composed of two different metals will generate an electromotive force when there is a temperature difference at both ends. The temperature is determined by measuring the electromotive force. The first thermocouple installation position 2 is near the bearing seats of the high-speed shaft and the low-speed shaft, and can sense the heat changes of the bearings in time. The second thermocouple installation position 1 is at the inlet and outlet of the oil cooler to monitor the changes in oil temperature and indirectly reflect the working temperature of the gearbox.

[0041] like Figure 2 As shown, the lower surface of the infrared thermal imager is provided with an adjustment base, which is installed in the side part of the cabin near the gear box and the bearing with the help of the adjustment base, and the lens of the infrared thermal imager faces the rear end of the gear box. The adjustment base covers the mounting plate 8 and the support frame 7. The mounting plate is vertically connected to the upper end of the support frame. An arc-shaped support plate 6 is arranged between the mounting plate and the support frame. An adjustment groove 5 is arranged on the surface of the mounting plate. The infrared thermal imager is connected to the inside of the adjustment groove through an adjustment bolt 4, as shown in FIG. Figure 3 As shown, the mounting plate 8 is vertically connected to the upper end of the support frame 7. Its main function is to provide a stable support plane and provide a basis for the installation and position adjustment of the infrared thermal imager. The arc-shaped support plate 6 arranged between the mounting plate 8 and the support frame 7 plays a role in enhancing the structural stability and dispersing the force. The arc-shaped design can effectively disperse the forces from different directions and reduce stress concentration, thereby improving the bearing capacity and durability of the entire adjustment base. The adjustment grooves arranged on the surface of the mounting plate provide a track and range limit for the position adjustment of the infrared thermal imager. By moving and fixing in the groove, the observation angle and position of the infrared thermal imager can be accurately adjusted. In addition, a protective cover is provided on the outside of the infrared thermal imager wire 9 to reduce the electromagnetic interference inside the cabin. The infrared thermal imager is connected to the inside of the adjustment groove by an adjustment bolt. The adjustment bolt can not only firmly fix the infrared thermal imager in the desired position, but also adjust the tightness when necessary so as to flexibly change the position of the infrared thermal imager.

[0042] like Figure 4 As shown, the first thermocouple is installed near the bearing seats of the high-speed shaft and the low-speed shaft through the first fixing fixture, wherein one side of the first fixing fixture is in the form of an annular clamp, and its main function is to tightly surround and fix the component to be installed. A wire groove 10 is provided on the other side of the first fixing fixture. This wire groove is used to orderly accommodate and arrange the thermocouple wires to avoid chaotic entanglement of the wires. The annular clamp 12 is connected to the outer side of the wire groove 10 by means of fixing bolts. The opening size of the first fixing fixture can be adjusted according to the tightening depth of the fixing bolts 11. This connection method can effectively fix the first thermocouple sensor firmly on the bearing surface to ensure the accuracy and stability of the measurement. At the same time, the thermocouple wires are reasonably distributed inside the wire groove, which helps to protect the wires and maintain the regularity of the line. The second fixing fixture adopts an adhesive clamp. The characteristic of this adhesive fixture is that it can firmly fix the second thermocouple sensor to the metal surface outside the gearbox through its own adhesive properties, wherein the probe of the second thermocouple sensor is connected to the inlet and outlet of the oil cooler of the gearbox in a fitting and abutting manner. Such a fitting and abutting design is intended to achieve accurate monitoring of oil temperature changes. Through close contact, the thermocouple sensor can sense subtle fluctuations in oil temperature in real time, thereby providing accurate and reliable temperature information for subsequent data analysis and system control.

[0043] like Figure 5As shown, the data acquisition card consists of a clock source, a timing controller and an embedded processor. The clock source plays a key role here. It is connected to the timing controller and the embedded processor respectively. Its main function is to provide accurate and stable clock signals for these two components. This clock signal is like an accurate metronome, ensuring the synchronization and accuracy of the entire data acquisition system. The timing controller establishes connections with the first thermocouple sensor, the second thermocouple sensor and the infrared thermal imager respectively through the analog-to-digital converter. Its role is to coordinate and control the signal acquisition process from these sensors and imagers to ensure the orderliness and consistency of data acquisition. The timing controller is also connected to the embedded processor to achieve synchronous signal acquisition, which means that during the entire data acquisition process, the signals generated by each sensor and imager can be accurately acquired under a unified time reference and uploaded to the host computer through the 4G network for two-way data transmission to complete data processing, thereby providing an effective data basis for subsequent data analysis and application. After receiving the data from the infrared thermal imager and the thermocouple sensor, the data acquisition card performs data fusion. First, the data format of the two is converted, and the raw data from the infrared thermal imager and the thermocouple sensor is converted into a unified data format, that is, the two are converted into specific temperature displays. For thermocouple sensors, Its output is usually a voltage value or a resistance value. These raw data are converted into corresponding temperature values ​​according to the characteristics of the thermocouple and the calibration data. In addition, the infrared thermal imager obtains the thermal radiation distribution image of the surface of the object, which is usually presented in the form of grayscale value or color image. The infrared thermal imager is calibrated using a standard blackbody source with a known temperature to establish the correspondence between the grayscale value of the thermal image and the actual temperature. The temperature value corresponding to each pixel is extracted from the processed thermal image, so that the output data of both are temperature values, and the data format conversion is completed. After that, the weighted average calculation of the data of the two is performed to obtain a specific temperature value. The basic idea is to assign a weight to the data of the thermocouple sensor and the infrared thermal imager, and then add the weighted values ​​and divide them by the sum of the weights to obtain the fused result. The formula for weighted average calculation is:

[0044] ,

[0045] in, Represents the temperature measured by the infrared thermal imager, Represented as the weight of the infrared thermal imager, is the temperature measured by the thermocouple sensor, It is expressed as the weight of the thermocouple sensor. In addition, the installation position of the wind turbine is different, and the temperature and electromagnetic interference it is subjected to are different, so the weight is determined according to the specific position. The weight when the temperature is most accurate is selected based on multiple realizations. The weight of the infrared thermal imager is generally about twice the weight of the thermocouple sensor. According to data fusion, the accuracy of temperature monitoring in the system can be improved to adapt to different environmental conditions in wind power generation.

[0046] The above are all preferred embodiments of the present utility model, and are not intended to limit the protection scope of the present utility model. Therefore, any equivalent changes made based on the structure, shape, and principle of the present utility model should be included in the protection scope of the present utility model.

Claims

1. A wind turbine generator condition monitoring system based on infrared thermal imaging, characterized in that: include: An infrared thermal imager, a thermocouple sensor unit and a data acquisition card, wherein the infrared thermal imager and the thermocouple sensor unit are installed in the cabin of the wind power generation equipment and are used to collect the temperature data inside the cabin. The data acquisition card is installed in the control cabinet of the wind turbine. The data acquisition card is connected to the infrared thermal imager and the thermocouple unit respectively through a data cable and is used to fuse the thermal imaging and thermocouple data. The data acquisition card uploads the fused data to a host computer.

2. A wind turbine generator status monitoring system based on infrared thermal imaging according to claim 1, characterized in that: The infrared thermal imager has a built-in embedded memory and an image processor. The embedded memory stores thermal images of the interior of the cabin under normal conditions. The embedded memory is connected to the image processor to provide reference images. The infrared thermal imager adopts a dual-lens infrared thermal imager.

3. A wind turbine generator status monitoring system based on infrared thermal imaging according to claim 2, characterized in that: An adjustment base is provided on the lower surface of the infrared thermal imager, and the infrared thermal imager is installed at a side position close to the gear box and the bearing in the cabin through the adjustment base, and the lens of the infrared thermal imager faces the rear end position of the gear box.

4. The wind turbine generator set condition monitoring system based on infrared thermal imaging according to claim 3 is characterized in that: The adjustment base includes a mounting plate and a support frame, the mounting plate is vertically connected to the upper end of the support frame, an arc-shaped support plate is provided between the mounting plate and the support frame, an adjustment groove is provided on the surface of the mounting plate, and the infrared thermal imager is connected to the inside of the adjustment groove through an adjustment bolt.

5. The wind turbine generator set condition monitoring system based on infrared thermal imaging according to claim 1, characterized in that: The thermocouple sensing unit is fixed to the gearbox and the bearing surface inside the cabin by means of a fixing fixture. The thermocouple sensing unit transmits data to a data acquisition card by means of a thermocouple wire. A protective sleeve is provided on the outside of the thermocouple wire.

6. The wind turbine generator system state monitoring system based on infrared thermal imaging according to claim 5 is characterized in that: The thermocouple sensing unit comprises a first thermocouple sensor and a second thermocouple sensor, and the first thermocouple sensor and the second thermocouple sensor are both connected to a signal input terminal of a data acquisition card through a thermocouple wire.

7. A wind turbine generator set condition monitoring system based on infrared thermal imaging according to claim 6, characterized in that: The fixing clamp includes a first fixing clamp and a second fixing clamp, one side of the first fixing clamp is an annular clamp, and the other side of the first fixing clamp is provided with a wire groove, the annular clamp is connected to the outer side of the wire groove by a fixing bolt, and is used to fix the first thermocouple sensor to the bearing surface, and the thermocouple wire is distributed inside the wire groove.

8. The wind turbine generator set condition monitoring system based on infrared thermal imaging according to claim 7, characterized in that: The second fixing fixture is an adhesive fixture, which fixes the second thermocouple sensor to the metal surface outside the gear box. The probe of the second thermocouple sensor is connected to the inlet and outlet of the oil cooler of the gear box in a fitting and abutting manner to monitor changes in oil temperature.

9. The wind turbine generator set condition monitoring system based on infrared thermal imaging according to claim 8, characterized in that: The data acquisition card includes a clock source, a timing controller and an embedded processor. The clock source is respectively connected to the timing controller and the embedded processor for providing a clock signal. The timing controller is respectively connected to the first thermocouple sensor, the second thermocouple sensor and the infrared thermal imager through an analog-to-digital converter. The timing controller is connected to the embedded processor for synchronous signal acquisition.

10. A wind turbine generator status monitoring system based on infrared thermal imaging according to claim 9, characterized in that: The data acquisition card has a built-in 4G communication network, and the data acquisition card uploads the fused thermocouple sensor data and infrared thermal imager data to a host computer through the 4G communication network for real-time data analysis.

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